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Page 1 of 24 Effective from ______ Draft Spec. no. RDSO/PE/SPEC/PS/0076-2012 (Rev.

0)
Date of Draft: 05.06.2012

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS AND STANDARDS ORGANISATION



lR;eso t;rs



ENERGY MANAGEMENT DIRECTORATE




SPECIFICATION

FOR


SOLAR PHOTOVOLTAIC BASED POWER SUPPLY FOR MANNED
LEVEL CROSSING GATES







Approved by




Executive Director/ EM





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SPECIFICATION FOR SOLAR PHOTOVOLTAIC BASED POWER SUPPLY FOR
MANNED LEVEL CROSSING GATES

1.0 FOREWORD

The Sun is an inexhaustible, reliable and non-polluting source of power.
Concerns over global climate change and resource scarcity make Solar
Photovoltaic (SPV) with battery backup an attractive power supply solution for
locations where grid power supply is not available. Such a system is therefore
well suited for manned Level Crossing Gates in non-RE sections. It will
greatly help towards the safety of road-rail intersections.

2.0 SCOPE

This specification covers the general and technical requirements of solar
photovoltaic system with battery backup, LED luminaires and fan for manned
level crossing gates in non-RE sections.

3.0 REFERENCE STANDARDS

IS: 12834:1989
(reaffirmed 2000)
Solar Photovoltaic Energy Systems -
Terminology
IEC : 61215 (2005) Crystalline silicon terrestrial photovoltaic (PV)
modules Design qualification and type approval
IEC: 61730 Pt 1 & 2 Photovoltaic (PV) module safety qualification
-Part 1: Requirements for construction
Part 2: Requirements for testing
IEC:60904-1(2006) Photovoltaic Devices- Part-I: Measurement of
Photovoltaic current-Voltage Characteristic
IEC: 61701 Salt mist corrosion testing of photovoltaic (PV)
modules
IEC: 60068 Environmental testing
IS:9000 Basic environmental testing procedure for
Electronic and electrical items.
Note: Latest version of the standards shall be referred to.

4.0 SYSTEM DESCRIPTION:

The Solar Photovoltaic (SPV) based system shall consist of the following
elements:

i) SPV Modules/Array to convert solar radiation to electricity.
ii) Module(s) mounting galvanized MS structure with necessary
accessories.
iii) Battery bank to store the electric energy generated by SPV panel during
daytime.
iv) Following chargers/ controllers will be provided:
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a) Solar charge controller to maintain the battery to the highest
possible State of Charge (SOC) while protecting the battery from
deep discharge (by the loads) or extended overcharge (by the PV
array).
b) A grid supplied charger (optional) that can accept 140-260 Volts,
1-phase, 50 Hz AC as input and charge the battery (it is an
optional item i.e. not to be supplied unless specifically called for in
the tender).
c) A Master Controller (this may be required, only if grid supplied
charger has been asked for) for coordinating the above charge
controllers/ chargers.
v) Blocking diode, preferably a Schottky diode, connected in series with
solar cells and storage battery to keep the battery from discharging
through the cell when there is no output or low output from the solar cell,
if such diode is not provided with the module itself.
vi) 48V to 12V DC-DC converter
vii) LED luminaires (with fixtures) for the goomtis illumination.
viii) LED outdoor luminaires (with fixtures) along with poles.
ix) Fan
x) Interconnecting copper wires/cables and hardwares.

5.0 GENERAL REQUIREMENTS

5.1 All wiring, enclosures and fixtures that are mounted outdoor must be resistant
to high humidity conditions, corrosion, insect and dust intrusion.

5.2 Metal equipment cases and frames in the system shall be properly grounded.

5.3 The main components shall be integrated in such a way as to allow
replacement (in case of failure) with a similarly functioning component of a
newer design or a different brand.

5.4 Electronic components used in controller or elsewhere in the system shall
generally meet the requirements mentioned below. Documentary evidence in
support of the same should be given.

i) All capacitors shall be rated for max. temp of 105 C.
ii) Resistances shall preferably be made of metal film of adequate rating
having a tolerance of not more than 5%.
iii) Switching devices such as transistors, IGBTs, MOSFETs, etc. shall
have minimum junction temp. of 150 C.
iv) Devices shall have adequate thermal margin at ambient temp. of 55 C.
v) Fibre glass epoxy of grade FR 4 or superior shall be used for PCB
boards having a nominal board thickness 1.6mm and copper cladding
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thickness of 70 micron. Both track width and spacing between the
tracks shall be 0.5 mm nominal and in no case shall be less than 0.3
mm. Assembled PCBs shall be given a conformal coating.

6.0 TECHNICAL REQUIREMENT

The charge controller will be required to charge 48V battery. A 48V to 12V
DC-DC converter shall convert the 48V DC battery output to 12V DC. The
lighting and fan loads shall work at a nominal voltage of 12V DC.

6.1.1 System load

Load on the solar system shall comprise of the following:

i) 3 nos. 4W (max) LED based luminaires with fixtures, two inside goomti
and one just outside the goomti and under shed (working for 12 to 20
hours/day i.e. dusk to dawn).
ii) 2 nos. 20W (max) LED luminaires with fixtures for illuminating the space
between the level crossing gates and the road stretches exiting from the
level crossing gates i.e. one on the same side as goomti and the other one
across the tracks. The 20W luminaires will be mounted on individual poles
(working for 12 hours/day i.e. dusk to dawn).
iii) 1 no. 18W (max) DC fan inside goomti (working for 24 hours/day in
summers).

6.1.2 The design of solar based power supply is based on the following factors:

i) Battery autonomy: 5 (1+4) days
ii) Operation period for indoor lighting: almost 20 hours.
iii) Operation period for outdoor lighting: almost 12 hours.
iv) Operation period for fan: almost 24 hours (in summer)
v) Solar Insolation: 5 peak sun hours/day

6.2 SPV Modules, their structure and associated accessories

6.2.1 The solar module shall be an assembly of suitable inter-connected crystalline
silicon solar cells. Imported SPV module or cell will not be accepted, unless
MNREs policy/ rules permit the same.

6.2.2 Minimum capacity of the solar panels installed shall be 640 Wp.

6.2.3 Individual Solar PV Module should conform to IEC:61215 Ed 2 or latest
Edition II, IEC : 61730 I :2007, IEC : 61730 II : 2007, manufactured in
India in a plant certified under ISO 9001 : 2008 and also type tested by an
accredited national/international testing laboratory. The Solar PV Module
should be made from single/poly crystalline Silicon Solar Cell connected in
series. PV modules to be used in a highly corrosive atmosphere (coastal
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areas, etc.) must qualify Salt Mist Corrosion testing as per IEC 61701; this
compliance and certification will not be required, unless the purchaser
specifically asks for the same in the tender.

6.2.4 SPV modules of similar output with 2% tolerance in single string shall be
employed to avoid array mismatch losses.

6.2.5 The conversion efficiency of Solar PV Cells used in the module shall not be
less than 15% and that of the module shall be not less than 14%.

6.2.6 Fill factor of the module shall not be less than 72%.

6.2.7 The solar module should have toughened, high transmissivity glass in front
side of the module for improved visibility and protection against
environmental hazards (rain, hail and storm) and weather proof
TEDLAR/POLYSTER back sheet.

6.2.8 The transparency of toughened glass used shall be > 91%, when measured
in actual sunlight by placing the glass plate perpendicular to the suns rays
through an air mass of 1.5. Certificate to this effect from a recognized test
house or their own laboratory shall be submitted at the time of type
approval.

6.2.9 The complete solar module shall be ensured for water-proof sealing in an
anodized Aluminum frame.

6.2.10 The output terminals of the module shall be provided on the back of the
solar PV module.

6.2.11 Terminal block shall be made of Noryl rubber or other suitable alternate
materials with weatherproof design (minimum IP-65) and shall have a
provision for opening/ replacing the cables, if required.

6.2.12 The system shall be virtually maintenance free (except for cleaning the top
glass of the solar panel depending on dust conditions at place of
installation).

6.2.13 The solar cell shall have surface anti-reflective coating to help to absorb
more light in all weather conditions.

6.2.14 A bird spike shall be provided to avoid bird sitting on the solar module at the
highest point of the array/module structure.

6.2.15 SPV module shall be highly reliable, lightweight and shall have a service life
of more than 25 years. SPV modules shall have a limited power loss of not
more than 10% of nominal output at the end of 12 years and not more than
20% at the end of 25 years.

6.2.16 Wherever more than one module is required, identical modules shall be
used.
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6.2.17 The rated output of any supplied module shall not vary by more than 3%
from the rated power of the module. Each module, therefore, has to be
tested and rating displayed.

6.2.18 The module/array junction boxes shall be dust, vermin- and waterproof and
made of FRP/ABS plastic having minimum IP 65 protection.

6.2.19 The Array Junction Box should preferably have maximum 08 input and 01
output with MOV and Terminal block.

6.2.20 Suitable markings are provided on the bus bar for easy identification and
cable ferrules shall be fitted at the cable termination points for identification.

6.2.21 The solar module shall be able to withstand the following environmental
conditions normally encountered at site:

i) Temp. ranging from -10C to +85C.
ii) Wind load: 200 km/h.
iii) Maximum mean hourly rainfall of 40 mm.
iv) Humidity level upto 95%.

6.2.22 Each PV module must use a RF identification tag (RFID), which must
contain the following information. The RFID can be inside or outside the
module laminate, but must be able to withstand harsh environmental
conditions.

i) Name of the manufacturer of PV Module
ii) Name of the Manufacturer of Solar cells
iii) Month and year of the manufacture (separately for solar cells and
module)
iv) Country of origin (separately for solar cells and module)
v) I-V curve for the module
vi) Peak Wattage, Im, Vm and FF for the module
vii) Unique Serial No and Model No of the module
viii) Date and year of obtaining IEC PV module qualification certificate
ix) Name of the test lab issuing IEC certificate
x) Other relevant information on traceability of solar cells and module as
per ISO 9000 series.

6.2.23 Marking:

Each module shall carry the following clear and indelible markings:

- Name, monogram or symbol of manufacturer;
- Type or model number;
- Serial number;
- Polarity of terminals or leads (colour coding is permissible);
- Open circuit voltage;
- Operating voltage;
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- Maximum system voltage for which the module is suitable;
- Operating current;
- Short circuit current;
- Date & place of manufacture;
- Weight of the module.

6.2.24 The SPV Module shall be tested as per Clause 13.1 of the spec.

6.2.25 The SPV modules shall be mounted on a structure which is designed to
withstand a wind speed of 200 kmph.

6.2.26 The array structure shall be made of hot dip galvanized MS angles of size
not less than 50mmX50mmX6mm. The galvanization thickness shall be at
least 85 microns. For coastal/ corrosive environments, the galvanization
thickness shall be at least 125 microns.

6.2.27 The foundation for module mounting structure shall be preferably 1:2:4 RCC
construction or any other combination based on the local site conditions for
which design details shall be submitted.

6.2.28 The clearance of the lowest part of the module structure and the developed
ground level shall not be less than 500 mm.

6.2.29 All fasteners used in the module mounting structure shall be of stainless
steel of grade SS 304.

6.3 Charge Controller, grid supplied charger and master controller

6.3.1 Solar charge controller

The Solar Charge Controller (SCC) will comply the following requirements:

(i) Suitable for charging T-Gel type VRLA as well as LMLA battery.
(ii) Suitable for receiving input from 640Wp solar PV system and
charging the battery.
(iii) The charge controller should comply to IEC 62509.
(iv) The charge controller should have IP 31 protection.
(v) It should be capable of handling 120% of modules rated current for one
hour duration.
(vi) MPPT technology.
(vii) Efficiency at rated output voltage and full load should not be less than
95%. Even at less than full load, efficiency should not be less than 90%
for upto 30% full load.
(viii) Temperature compensated charging.
(ix) Provision of blocking diode, preferably a Schottky diode, to prevent the
battery from discharging itself through the SPV system/ charge
controller. The current capacity of the blocking diode shall be 50%
higher than the short circuit current at STC. The peak inverse voltage
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(PIV) of the diode shall be at least equal to the open circuit battery
voltage.
(x) On the SPV power source side, the charge controller shall be protected
against lightning and surges. The MOVs used shall be rated for at least
10KA at 8/20 Sec. The voltage rating of the MOVs shall be at least
10V higher than the specified value of the SPV array.
(xi) Protection shall also be provided against the following: battery
overload, battery overcharge, short circuit and reverse polarity. Auto
resettable reverse polarity protection should be provided.
(xii) Max. voltage drop between SPV module and battery terminal (with all
the loads off and max. current from the SPV module) shall not be
more than 0.8V and that between battery and output terminals of load
(with all the loads on and no current from SPV module) shall not be
more than 0.7V.
(xiii) The charge controller shall incorporate the auto, bulk and float charging
methods. Equalization charging facility should also be available.
(xiv) The self consumption of the solar charge controller shall be not more
than 0.1% of the nominal charging current.
(xv) The charge controller shall withstand a test voltage of 2,000V applied
between DC line terminals and earth for one minute without any
puncture and arcing.
(xvi) In case the master controller is not provided, then the charge controller
should have the feature of load disconnect to protect the battery from
deep discharge.
(xvii) The charge controller should comply the following environmental tests
with the charge controller working at full load as per IEC 60068/ IS
9000.
i. Dry Heat Test - 70C2C for 16 hours
ii. Damp Heat Test (Steady state) - 40C, 95% RH for 4 days
iii. Damp Heat Test (Cyclic) - 40C, 93% RH for 6 cycles
iv. Cold Test - 0C for 16 hours
v. Change of temperature Test -10C to 70C for 3 cycles
vi. Dust test for 1 hour
vii. Salt mist Test

6.3.2 Grid supplied charger (optional item)

If grid electricity supply is available at a level crossing gate, then the
purchaser can (optionally) order a battery charger which would be fed from
grid electricity supply. The charger will work with 140 260V, 50 Hz AC input,
will be based on PWM technology and shall be suitable for charging the
battery as per the various stages of battery charging as mentioned in solar
charge controller. Input to the charger shall be protected against lightning and
surge. Unless specifically asked for by the purchaser in the tender, the
aforesaid grid fed battery charger will not be supplied.

6.3.3 Master controller (optional item)
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If grid supplied battery charger has been asked for in the tender, then a
Master Controller will also be provided and the same will be responsible for
integrating the above charge controllers/ chargers so as to maintain the
battery to the highest possible State of Charge (SOC) while protecting the
battery from deep discharge or extended overcharge. In as far as possible,
renewable energy will be utilized for battery charging. But if renewable energy
supply is low or not available, then the master controller will enable the battery
to be charged through the grid supplied battery charger. It should be possible
for the purchaser to set the battery voltage at which the grid supplied charger
will be cut in. The controller will have dusk to dawn switching for outdoor
lighting.

6.3.4 Indications and meters

Relevant meters should be provided for voltage, current and indication for
Low Battery, Battery on charge and Battery fully charged. Detailed scheme
shall be submitted at design/ drawing approval stage.

6.3.5 Charge controller testing

Tests shall be conducted in the following order:
1 . Functional Test including overload cutoff 100%.
2 . Insulation Resistance of at least 50 M. The test is to be performed
between shorted DC output terminals and earth, shorted DC/AC input
terminals and earth and shorted DC output terminals and shorted DC/AC
terminals.
3. High Voltage Test as per Clause 6.3.1(xv).
4. Various protections specified for the charge controller.
5 . Environmental testing
6. Self Consumption

6.4 48V to 12V DC-DC Converter

6.4.1 The 48V to 12V converter shall convert 48V DC received from charge
controller output to 12V DC i.e. the voltage at which the loads (LED luminaires
and fan) shall function.

6.4.2 Output current handling capacity shall be at least 10A.

6.4.3 The converter shall have a minimum efficiency of 95% for currents ranging
from 2A to the maximum current rating.

6.4.4 Protection shall be provided against the following: overload, short circuit and
reverse polarity. Auto resettable reverse polarity protection should be
provided.

6.4.5 The output ripple shall not be more than 1% when measured at 10A output.

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6.5 Battery Bank:

6.5.1 Battery Bank shall be either low maintenance lead acid tubular type (LM)
complying to IS 1651: 1991 or Tubular Gel type Valve regulated lead acid
battery (VRLA) type complying to IEC 60896 21 & 22 (battery type is to be
specified by the purchaser). Since it will be difficult for maintenance staff to
visit the level crossing gates, it is recommended that the purchaser should
consider specifying T-gel type VRLA battery for this application.

6.5.2 The storage battery Bank shall have 48V 150Ah (C10) LM (Tubular batteries)
gel type VRLA batteries. The LM Battery shall be Tubular Lead Acid, Low
Maintenance type with low antimony lead alloy plates and ceramic vent
plugs and water topping interval of 1 year which are specially designed to
be charged and discharged frequently and can handle heavy discharges time
after time with minimum charging efficiency of not less than 90%.

6.5.3 The container material shall be Polypropylene in case of LM battery and
Polypropylene/ABS in case of gel type VRLA battery.

6.5.4 Both LM and gel type VRLA Battery shall have a design life expectancy of
more than 5 years at 50% DOD at 27C.

6.5.5 The permissible self-discharge rate shall be less than 3% for LMLA batteries
and 2% for T-gel VRLA batteries of the rated capacity per month at 27C.

6.5.6 The charging instructions shall be provided along with the batteries.

6.5.7 The LM batteries shall be provided with micro porous vent plugs and acid
level indicator.

6.5.8 The LM and gel type VRLA batteries shall be discharged upto 80% DOD.

6.5.9 Suitable Battery Box made of Polycarbonate or M.S. fabricated with acid proof
paint shall be provided to house the battery. Size of the battery box should
also be compatible for accommodating train lighting batteries at a later date

6.5.10 Make of the battery shall be approved at the system design stage.

6.5.11 If released batteries from railways are used in place of above battery bank,
then the prospective supplier of the system shall study these batteries and
integrate them with the system without affecting the overall performance.

6.6 Battery Testing

Both LM & Tubular Gel batteries shall have third party certifications for life test
as per IEC 61427 for minimum requirement of 13 units @150cycles / unit
equalling to 5 years life. All routine tests as per applicable standards shall be
conducted on the batteries.

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Performance characteristics curves as indicated below of the offered battery
shall be submitted:

i) Charging-discharging characteristics at various temperature and cell
voltage.
ii) Self discharge at various ambient temperatures.
iii) Cell voltage vs. State of charge.
iv) Capacity vs. Rate of discharge.
v) State of charge vs. Sp. Gravity of electrolyte.
vi) Depth of discharge vs. No. of cycles.

6.7 LED Lamp and fixtures

Instead of designing/ manufacturing a special luminaire, a commercially
available LED luminaire (or an improved version of it) of good repute/
performance record, if available, will be preferable. Unless otherwise specified
in the following sub-clauses, LED/ luminaire manufacturers data-sheet/
conformance certificate will be accepted in lieu of tests.

6.7.1 Rated Voltage and Power: Voltage: 12V DC; Power: 20W max for outdoor
and 4W max for indoor (power ratings are inclusive of driver losses).

6.7.2 Light intensity: Minimum 350 (4W)/ 1600 (20W) system lumens. Third party
certificates for compliance can be accepted. Else, this is required to be
demonstrated through a test.

6.7.3 Minimum luminaire efficacy of 80 lumen/W is required for outdoor luminaire.
LM 79 report is required to be submitted in this regard. Else, this is required to
be demonstrated through a test.

6.7.4 LED type White LEDs with CCT range of 5500-6500 K temperature
(preferably surface mount power LEDs). Colour Binning should comply
existing ANSI standard C78.377A. White Point Stability of LED should be
within 7 McAdam Step. LED used should be of SMD type only.

6.7.5 Colour Rendering Index (CRI) shall not be less than 70.

6.7.6 Minimum LED efficacy shall be 100 lm @ 350mA drive current to meet
required LUX level.

6.7.7 L70 life of LED shall be more than 50,000 hours at soldering point
temperature of 85 deg C and at luminaire operating current. The life time
projection should be based on LM-80 test data and corresponding TM21
projection method for the corresponding driving currents at which the LEDs
are driven.

6.7.8 Junction to soldering point thermal resistance should be less than 10 degC/W.
Thermal pad of LED shall be isolated from Electrical path and shall be directly
soldered to MCPCB for efficient heat dissipation.
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6.7.9 Maximum LED Junction Temperature 150 Deg C rating for better capacity to
handle heat.

6.7.10 LED used shall be of NICHIA/ OSRAM/ SEOUL SEMICONDUCTOR/
PHILLIPS LUMILEDS/ LEDNIUM/ CREE make.

6.7.11 Outdoor LED fixing arrangement - Mounted on metal core PCB fixed to
Aluminum heat sink for 20W luminaire.

6.7.12 The 20W LED outdoor luminaires shall each be mounted on 5m height from
ground level on galvanized 6m MS poles with necessary accessories i.e. one
on each of the two poles on either side of the track.

6.7.13 Avg. illuminance delivered by outdoor luminaire shall be 8 lux at ground level
(5m from the luminaire) shall be measured using 9 point method as defined
in Annexure 2. The ratio of minimum to average illumination shall be at least
0.4 and the transverse uniformity ratio i.e. minimum to maximum illumination
shall be at least 0.33. Lux level. Conformance to proposed designed scheme
shall be tested. Luminaires conforming to desired requirements will be
approved. Third party certificates for compliance shall be accepted. Else, this
is required to be demonstrated through a test.

6.7.14 Indoor LED Fixture: ABS plastic/Aluminum fixture with acrylic cover with 120
degree viewing angle.

6.7.15 Outdoor LED Fixture: ABS plastic/ Aluminum fixture with acrylic cover with
120 degree viewing angle and IP 65 protection.

6.7.16 The LED luminaire shall comply to IEC 60598. Third party certificates for
compliance shall be accepted. Else, this shall be demonstrated through tests.

6.7.17 The temperature of the heat sink shall not be greater than 20C above
ambient temperature even after 6 hours of continuous operation.

6.7.18 The LED driver DC current regulation shall be better than 3%.

6.7.19 The LED controlgear shall comply to IS 15885 (Part 2 /Sec 13)/ IEC 61347-2-
13 and IS 16104/ IEC 62384. Third party certificates for compliance shall be
accepted. Else,this shall be demonstrated through a test.

6.7.20 The connecting wires used inside the luminaire shall be low smoke, halogen
free, fire retardant e-beam/PTFE cable.

6.7.21 Automatic dusk to dawn switching of the LED streetlights shall be integrated
in the system.

6.7.22 The luminaire should be LM-79 compliant. Typical light distribution should be
as per the polar curve given:

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6.8 Fan

A DC wall mounted bracket fan shall be provided. A commercially available
market product of good repute/ performance record will be preferable. Unless
otherwise specified, fan manufacturers data-sheet/ conformance certificate
will be accepted in lieu of tests. Indicative technical parameters of the fan can
be as follows. But if it so happens that a commercially available market
product of good repute/ performance record has somewhat different
parameters, the same can also be accepted by the purchaser with the over-
riding condition that the power consumption of fan will not exceed 20W in any
case.

Voltage rating: 12V DC
Power: 18W (max)
Air flow: More than 0.25 m/sec.
Fan sweep: 300 mm
Motor insulation: F Class
Temp rise: less than 65 C above ambient.
Public Safety: Shroud shall be provided for protection.

6.9 Cables and Hardware

6.9.1 Cabling of the system shall be as short as possible to minimize the voltage
drop in the wiring

6.9.2 Cable shall meet IS 1554/ 694 Part 1:1988 and shall be of 650 V/ 1.1 kV.

6.9.3 The module/ array wiring shall be water and UV resistant and suitable for
Solar system application. The cables used shall be TUV 2Pfg 1169/08.2007
or VDE EPV 01:2008-02 or UL4703 certified

6.9.4 All wiring must be sized to keep line voltage losses to less than 3% in each
sub-circuit and to allow the circuit to operate within the ampere rating of the
wire.

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6.9.5 Components and hardware shall be vandal and theft resistant. All parts shall
be corrosion-resistant.

6.10 Protections

6.10.1 Adequate protection shall be incorporated under no-load conditions (i.e. when
the system is ON and there is no load) from master controller output side.

6.10.2 If any other protection is necessary, the same will be deemed to be a part of
the specification.

6.11 Marking:

Each system shall carry the following clear and indelible markings on the
controller:
- Name, monogram or symbol of system integrator;
- Type or model number;
- Serial number;
- Polarity of terminals or leads (colour coding is permissible);
- Output voltage.
- Max. Power output
- Date of supply
- Battery type
- Total AH
- No./ AH of batteries

7.0 INSTALLATION & COMMISSIONING:

The installation shall be done by the supplier/manufacturer who is responsible
for system performance, direction of installation and structural stability. The
supplier shall conduct a detailed site assessment. The installer shall obtain
data specific to the site, rather than relying on general data.

8.0 DOCUMENTATION:

The supplier shall provide easy-to-use illustrated installation and operation
manual in English and local language for easy installation and trouble-free
usage. The manual shall contain complete system details such as array
layout, schematic of the system, working principle, clear instruction on regular
maintenance, troubleshooting of the system and emergency shutdown
procedures.

9.0 GUARANTEE/WARRANTY (Deleted).

10.0 LOG BOOKS

Railways shall maintain a logbook detailing inspection and operating
activities. This log book must be kept in a secure place and shall be made
available, whenever required for inspection. Testing of all protection devices
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shall be carried out at regular intervals (no longer than six months) by the
customer and recorded in the log book.

11.0 DESIGN APPROVAL

Design for complete system and sub-systems shall be approved by RDSO at
design stage before manufacture of prototype conforming to this specification.
The criteria for selection of sub-system / component shall be based on sound
engineering practice conforming to the International/ Indian Standards
wherever specific standard is not specified in this specification. The detailed
calculation/simulated results shall be submitted in support of system/sub-
system rating. Adequate safety margin as stipulated in respective
specification shall be used.

12.0 PROTOTYPE APPROVAL

The prototype system shall be offered to RDSO (or any other agency
nominated by Indian Railways for testing and approval.

For certain tests, the type testing authority i.e. RDSO may choose to rely upon
previous type test reports/conformance certificates, as long as they pertain to
similar design and comparable rating. However, the manufacturer cannot
demand this as a matter of right.

Until the railways are able to issue their vendor list, they may in the interim
period invite tender/ place order with the provision of accepting the material
on the basis of firms written clause-by-clause confirmation of the spec. and
acceptance test alone, in instances where such recourse is considered
necessary by CEE. In absence of any mention to the contrary in the tender
and purchase order, it will be deemed that both type-test clearance as well as
acceptance test will be involved.

13.0 Tests

13.1 Test on SPV Module

S.N. Name of Test Type
Test
Routine
Test
Acceptance
Test
Method
1. Visual Examination Refer Annexure 1
2. Design Qualification * IEC 61215
3. Safety Test * IEC 61730
4. Photo Electrical
Conversion
Efficiency






By Sun simulator
on each module
5. Fill Factor By Sun simulator
on each module
6. Transmitivity of As per Cl 6.2.8
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Glass
7. Rated output of
module
By Sun simulator
on each module
8. Module mismatch
test
Refer Cl 6.2.17
9. Array mismatch test Refer Cl 6.2.4
11. Terminal block Refer Cl 6.2.11
12. Provision of Bird
Spike
Refer Cl 6.2.14
13. Provision of RFID
tag with requisite
details






Refer Cl 6.2.22
14. Environmental tests Refer Annexure 1
14 Marking Refer Cl 6.2.23
* Copy of the latest conformance certificates should be asked for
13.2 Tests on Module Mounting Structure

S.N. Name of Test Type
Test
Routine
Test
Acceptance
Test
Method
1. Visual Examination





Refer Cl 6.2.25,
6.2.26, 6.2.27,
6.2.28 and
6.2.29
2. Dimension



As per
manufacturers
data sheet
3. Design calculation on
Tower wind withstand
capability




Refer Cl 6.2.25
4. Clearance between
module and ground




Refer Cl 6.2.28
5. Galvanization thickness Refer Cl 6.2.26
6. Foundation Refer Cl 6.2.27

13.3 Tests on module junction box, Array sub-main and main Junction Box

S.N. Name of Test Type
Test
Routine
Test
Acceptance
Test
Method
1. Visual Examination





Refer Cl 6.2.18,
6.2.19, 6.2.20
2. Material Refer Cl 6.2.18
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3. IP Protection Refer Cl 6.2.18
4. Surge Protection Refer Cl 6.2.19

13.4 Test on Solar Charge Controller

S.N. Name of Test Type
Test
Routine
Test
Acceptance
Test
Method
1. Visual Examination
2. Compliance to IEC:
62509




IEC: 62509
3. Auto, bulk, float and
equalization charging of
battery




Refer Cl.
6.3.1-(xiii)
4. MPPT Technology



As per
design of
supplier
5. Overload test Refer Cl.
6.3.1-(v)
6. Efficiency Refer Cl.
6.3.1-(vii)
7. Temp. Compensation Refer Cl.
6.3.1-(viii)
8. Protection Test Refer Cl.
6.3.1-(xi)
9. IP protectiion Refer Cl.
6.3.1-(iv)
10. Surge protection Refer Cl.
6.3.1-(x)
11. Operational Test Refer Cl.
6.3.1
12. Self-Consumption Test Refer Cl.
6.3.1-(xiv)
13. Blocking Diode Refer Cl.
6.3.1-(viii)
14. Over Voltage Test Refer Cl.
6.3.1-(xv)
15. Environmental Test Refer Cl.
6.3.1-(xvi)
16. Suitability for both T-Gel
VRLA and LMLA
Refer Cl.
6.3.1-(i)
17. Voltage drop test Refer Cl
6.3.1 (xii)
18. Checking of electronic
components
Refer Cl 5.4

13.5 Tests on Battery

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S.N. Name of Test Type
Test
Routine
Test
Acceptance
Test
Method
1. Visual Examination
2. Battery Type



Refer Cl.
6.5.1
3. Battery Voltage and AH



Refer Cl.
6.5.2
4. Charging Efficiency * * Refer Cl.
6.5.2
5. Battery Life * * Refer Cl.
6.5.4
6. Enclosure material Refer Cl.
6.5.3
7. Self-Discharge Test * * Refer Cl.
6.5.5
8. Battery Characteristics * * Refer Cl. 6.6
* To be relied on datasheets and test reports
13.6 Tests on LED Lamp and Fixture

S.N. Name of Test Type
Test
Routine
Test
Acceptance
Test
Method
1. Visual Examination
2. Rated Power of the
luminaire




Refer Cl.
6.7.1
3. Light Intensity



Refer Cl.
6.7.2
4. Lumen efficacy of the
luminaire
Refer Cl.
6.7.3 and
6.7.6
5. LED Type ** Refer Cl.
6.7.4, 6.7.6,
6.7.7, 6.7.8,
6.7.9,
6.7.10,
6.7.14 and
6.7.15
6. LM-80 and TM-21
reports for L70 Life of
LEDs
** ** Refer Cl.
6.7.7
7. LED Junction Temp ** ** Refer Cl.
6.7.9
8. Heat Dissipation for LED ** ** Refer Cl.
6.7.8
9. Lux Level Refer Cl.
6.7.13
10. LED Enclosure Refer Cl.
6.7.14 and
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6.7.15
11. IP Protection * Refer Cl.
6.7.15
12. Heat Sink Temp Refer Cl.
6.7.17
13. LED Driver Regulation Refer Cl.
6.7.18
14. LED Control Gear
Compliance
* Refer Cl.
6.7.19
15. Dusk to Dawn Switching Refer Cl.
6.7.21
16. LM-79 Compliant * * Refer Cl.
6.7.22
17. Checking of electronic
components
Refer Cl 5.4
* Checking of test reports
** Checking og LED datasheets
13.7 Tests on Cables and Hardware


S.N. Name of Test Type
Test
Routine
Test
Acceptance
Test
Method
1. Visual Examination





Refer Cl 6.13
2. Voltage rating Refer Cl 6.9.2
3. Voltage Drop Test Refer Cl 6.9.5

13.8 Test on Fan

During acceptance of the system, the fan should be visually examined, its
rating plate should be checked for correctness of voltage, power, motor
insulation, air flow, sweep and the fan should be subjected to a simple
functional check. Only power consumption at rated voltage should be
measured.



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Annexure - 1

Quality Testing of PV-Module

Solar PV module shall be certified according to IEC 61215. The qualification testing
procedure is defined in IEC 61215 to examine the impact of mechanical, thermal and
electrical stress on power output. Bidder shall submit appropriate type approval
certificate for the offered solar modules from IEC accredited laboratories.

Method of Testing

1.0 Visual Inspection:
Each module shall be carefully inspected under an illumination of not less
than1000 lux for the following conditions:

i) cracked, bent, misaligned or torn external surfaces
ii) broken/ cracked cells
iii) faulty interconnections or joints
iv) cells touching one another or the frame
v) failure of adhesive bonds, bubbles or delaminations forming a
continuous path between a cell and edge of the module
vi) faulty terminations, exposed live electrical parts
vii) Junction box should have common terminals with suitable bypass
diode for preventing hot spot problem.

2.0 Performance at STC: (Clause 10.1 of IEC 61215:2005)
The current-voltage characteristics of the module shall be determined in
accordance with IEC 60904-1 at a specific set of irradiance and temperature
conditions.

Performance of PV-Module shall be generally evaluated at Standard-Test-
Conditions (STC) as defined in IEC 60904 standards:

i) cell temp of 25 C,
ii) incident solar irradiance of 1000W/m2,
iii) spectral distribution of light spectrum with an air mass AM=1.5

3.0 ENVIRONMENTAL TESTING
Following environmental tests shall be conducted on offered module or on
module of similar design, for initial clearance of the offered system:


Test Test Details
Relevant standards
Cold Test Temp. (-) 10
0
C
Duration: 16 hrs.
IEC-68-2-1
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Dry Heat Temp. (+) 70
0
C
Duration: 16 hrs
IEC-68-2-2
Salt spray
*


Temp. (+) 35
0
C, RH
95%
Duration: 2 hrs spray
and 22 hrs conditioning
No. of Cycle : 01
IEC-68-2-11 Test Ka
Wind Pressure equivalent to
an air velocity of 200
km/hr.

Rain Test as required in the
mentioned standards
JSS: 55555 (Test No. 12)
Dust Temp : 40C, RH <
50% Duration 1 hr
JSS: 55555 (Test No. 14)

* If compliance to IEC 61701 has been asked by the purchaser, then this test will not be required
Note: Before and after each environmental test, the solar modules shall be subjected to performance
test on sun simulator and insulation resistance test. Degradation of the maximum output power
shall not exceed 5% of the value measured before the test.

4.0 Acceptance Criteria:
The Module is deemed to have passed the tests if the sample meets the
following criteria:

There is no evidence of a major visual defect such as a cracked or
broken window, bubbles or de-lamination in the encapsulant etc.
There is no cell breakage and no water infiltration into terminal boxes.
No sample exhibits any open circuit or ground fault.
No visible evidence of major defects that may affect the performance of
the module.
Insulation Resistance not less than 50M-ohm at 500 V DC.
Degradation of performance may not exceed 5% after each single test
or 8% after the whole sequence.

-------------
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Annexure - 2

MEASURING STREET LIGHTING LUX LEVELS

9 point method

Basics:
Divides the section between two poles into 4 quadrants of equal size
Measures the Lux levels at four corners of each quadrant
Takes the average of each quadrants
Finds the average of the all the four quadrants
Distance between two poles shall be at 15 m and the width of the road is to be
taken as the height of the pole i.e., 5 m.
Pole 1 Mid-
Point
Pole
2
Edge of the road near
light
P1 P2 P3
Mid road P4 P5 P6
opposite edge of the
road
P7 P8 P9

Average Lux levels = (P1+P3+P9+P7)/16 + (P2+P6+P8+P4)/8 + (P5)/16


























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Annexure - 3

TECHNICAL DETAILS TO BE FURNISHED BY THE PURCHASER IN HIS
REQUISITION/ TENDER

1. Battery
i) Battery type (see Cl. 6.5.1 )


2. SPV Module
i) Is Salt Mist Corrosion Testing required (see Cl.
6.2.3) (Yes/No)


3. Module mounting Structure

i) Galvanization thickness required required (see Cl. 6.2.26) (125/85 microns)

4. Grid supplied charger
i) Are grid supplied charger and master controller
required (see Cl. 4.0-iv-b & c) (Yes/No)




























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Annexure - 4

TECHNICAL DATA TO BE FURNISHED BY THE TENDERER IN HIS OFFER


1. SPV Module
i) Make and model no.
ii) Power rating

2. SPV Moounting Structure
i) Galvanization thickness of the structure
ii) Angle dimensions used

3. Charge Controllers
(please provide detail for solar charge controller; if the purchaser has also asked
for a grid supplied charger, then provide details thereof and that of the master
controller)
1. Make and model no.
2. Ratings


4. Battery
i) Make and model no.
ii) Battery type
iii) VAH rating of battery (mention voltage as
well as AH)


5. LED luminaires
i) Make and model no.
ii) Voltage Rating (V)
iii) Power Rating (W)
iv) Luminous efficacy of luminaire (lm/W)

6. Fan
i) Make and model no.
ii) Voltage Rating (V)
iii) Power Rating (W)
iv) Air Flow (cum/sec)
v) Sweep (mm)